Method of forming coded cards for data-processing machines



ug- 3 l965 L. J. FINLAYSON r-:TAL 3,198,048

METHOD OF FORMING CODED CARDS FOR DATA-PROCESSING MACHINES Filed Feb. 19, 1962 2 Sheets-Sheet l 36, l r N OO o o f o OO 42 O 2 g O /60 oo o OO .r1-g A O o o O oo 62m OO OO f 44/ oo oo i o m oo o o 1 o N oo i oo d (5, OO OO C L: o l l 42 8 OO I O l l I OO O/ i l (l l l I f/L J 60 38 )l-J 56) l36 3,6 )8 50 L L l l l (c, 1:, o i fOO o OoN CO C' l O O i n Q 4t2-zij o g3 g o i 1: g QQ L OO g O |c .5.1 D como@ rn o ,60 '1 m C O x O if; @i 964 OO 60/" 'JO C) I' 6km i 1-/-44 fj 1GO 00| OO oo l oo c l o Oo C: m /J C l O N u) O l |00 on o L11 LU oo I o m S 0c Oo 5g Oo i I C' ,f i (UO: OO o O I :QQ O I i CI OO i lo 1 @ol oo o i L j -T" '!"J" if ll l J 38 b"- 38 T54 60 52 INVENTORS Loa/1N JF/NLAYSON E//@ET H. CAGLEY www ,4T PNEYS Aug 3, 1965 L. J. FlNLAYsoN ETAL. 3,198,048

METHOD OF FORMING CODED CARDS FOR DATA-PROCESSING MACHINES Filed F'eb. 19, 1962 2 Sheets-Sheet 2 24C] mL- f 30 4//0 oo [l 0o OO OO 2 O0 E 0 OO OO W22 oo oo /8 O/ 2O D oo f/4 OO /6 [l O o OO Oo oo odr ooo ooo ooooooo COD E 'l 3 QQ COSC v Z 3G09 Oooooo o ooo OO o ao oo Oo o ooooo Q l A@ 42 44 40 42 INVENTORS UGA/v ZF/NLA Yso/v Maw ATTORNEYS United States Patent O resa, ser. No. maar (el. :is-ss) This invention relates to coded cards of the type used to program electronic or electro-mechanical data processing machines together with the methods employed in fabricating same.

Cards including some type of coded indicia in the form of punched holes, magnetic ink, notched edges and the like are widely employed in automatic data processing equipment to program the machine so as to deliver the desired information. These code cards also duplicate the coded information in printed form so that the operator can malle efcient use thereof without having to learn and decipher the code.

The data-processing machines that utilize these coded cards as the means by which they are programmed require extremely precise register between the code-forming indicia and the particular elements of the machine that are actuated thereby. This is particularly true of the punched-hole-type code cards which customarily tunc tion to actuate .a selected group of microswitches by moving them from a normally open into closed position against a spring bias while allowing7 the remaining switches to stay open. Now, if any misalignrnent of the code holes and the associated microswitches or similar functional element of the machine occurs, it becomes obvious that the correct group of switches will not be actuated and the machine becomes improperly programmed. The fact that this has occurred may or may not be indicated by the data delivered and, in any event, malfunctions of this type should be avoided if at all possible.

Accordingly, it becomes of utmost importance to manufacture the coded programming cards to extremely precise tolerances so that the difficulties of the type mentioned briefly above can be avoided. rlhese tolerances are critical both with regard to the size and shape of the card as well as the location of the code-forming indicia in relation to these dimensions.

The data-processing machines that are programmed by these coded cards include a minimum of two guide-torming stops that engage adjacent edges of the card and locate the code-forming indicia carried thereby in proper relation to the elements of the machine to be actuated. This means, of course, that the two stop-engaging edges bear a critical relationship to the code-forming indicia and the dimensional spacing therebetween must be main tained to extremely precise tolerances. Obviously, when only two adjacent edges of each card engage stops and are, therefore, critical, it becomes possible to blank out four cards at a time from a single sheet of stock and still maintain the desired relationship between the stopengaging'edges and the code-forming indicia. rhis can be accomplished by leaving the tour cards joined together along only their non-critical edges for later separation by conventional stack-cutting methods while forming the critical edges thereof with the bl-anking die along the outside edges of the card stock. lt happens, however, that many of these machines are so designed that the ele ments actuated by the code-forming indicia are located so that only one-half of the card need be coded. This means that a complete set of cards can be eliminated by doubling-up on each card so that two separate codes ice are carried by each one. in other words, the top halt of the card would carry one code and the botten halt another so that the machine would be programmed differently depending upon winch of the two codes was used as the means for actuating the sensing elements. In actual practice, this is accomplished by reversing the card tenter-bottom or side-tor-side so that the printed deciphers of the two codes appear on opposite faces rather than opposite halves of the same face. rEhe net result of this doubling-up approach is to make a third edge critical insofar .as its space or dimensional relationship to the code-forming indicia is concerned. When this is the case, the maximum number of cards that can be blanked out of a single sheet of stock while still preservmg the dimensional tolerances between the threeA critical edges and the code-forming indicia is reduced from tour to two as the only remaining non-critical edge that can be gang-cut and along which the cards can remain )joined together is the single edge that at no time comes into contact with a guide-forming stop in the machine.

Carrying this doubling-up concept one step further, it is also posible to utilize only a quarter of the card for each code so that four different ones can appear on the saine card. By utilizing a square card, it is possible to place as many as eight separate codes on a single card; however, from the standpoint of dimensional criticality, the same problems are involved with four as eight. In the tour-code card, the usual arrangement is to place the first code in the upper left hand quadrant and the printed decipher therefor along the top-halt reading right side up. The second code would be placed in the lower righthand quadrant and its decipher along the bottom halt of the same face but upside down. Thus, to utilize the second code, the card would be turned 189 to bring the bottom edge to the top but not flipped over. The third code would be located in the upper right-hand quadrant or, to be more accurate, the upper lett-hand quadrant with the card dipped over. This would place the decipher for the third code on the baci@ u per-half of the card reading right-side-up as was the case with the rst decipher, Finally, the fourth code would appear in the lower left hand quadrant, i.e. the lower right-hand corner with the card reversed tace-to-face. its decipher would be on the lower-halt" of the back of the card upside down.

Now, in this situation, where the card is used with the same face up and reversed edge-foredge and also dipped over face-ior-tace, it becomes apparent that all four edges bear critical relationships to one or more or the code-forming indicia. It was felt, hertotore, that because all four edges were critical, the cards had to be blanlied out oue-atatime the precise tolerances required were to be maintained.

lerhaps the most w'dfly used of the data-processing machines that is pro`I AAned by a punched card carrying -four separate and distinct codes is one wherein the guideforming stop that engages the bottom edge of the card is of the non-continuous or interrupted type having spaced supports that Contact the card edge along only a portion of its overal1 length. It has now been found in accordance with the teaching ot the instant invention that two rectangular prograrnrnin7 cards having four critical edges and carrying four or more separate codes can, in tact, be blaniied from a sincle sheet of card stocl; provided the data-processing mac in which they are to be used employs at least one non-continuous stop of the type aforementioned. rthis is .accomplished by slotting the stock along the common edge between the two cards formino an accurate edge and each positioned to Vengage the interrupted stop whi e, at the same time, leaving the two cards connected by a shared tab that can be gang-cut following the printing operation to separate sacando er) the cards. his tab is located so that it does not contact the non-continuous stop in be data-processing machine; therefore, the accuracy with which it is cut is immaterial as long as the edges delined by the slots are not altered.

lt is possible with a suitable die to blank out both cards of the pair thereof from a single sheet of stock with `a single stroke of the die leaving them connected to one another only along their common tabs; however, the savings realized by so doing when compared with blanking the two cards separately ou-t of the same piece of stock are not appreciable, especially when the increased cost of a double-card die over a single is considered. The real savings come from being able to print both cards at the same time while they remain joined together by the connecting tab and also the substantial reduction in lhandling the cards two-at-a-time. Savings up to fifty percent are being achieved `at t c present time by utilizing the present methods when compared with the prior art method by which the cards were cut and printed singly.

lt is, therefore, Vthe principal object of the present invention to provide a novel and improved rectangular coded programming card for data processing machines together with the methods employed in cutting all four edges thereof to exact dimensions.

Another object is to provide a method for fabricating coded cards wherein a pair of cards are cut in end-to-end face-up relation from a single sheet of stock and remain joined along `a common edge while being printed.

Still another object is to provide an improved punchedrole-type .coded programtnimy card specifically adapted for use in data-processing machines having at least one interrupted card-positioning guideway or stop.

An additional objective of the invention is the provision of a card-cutting method capable of producing programming cards having four critical edges and four or more separate codes that maintain dimensional tolerances several times more accurate than have been achieved heretofore with other methods.

Further objects of the invention are to provide a method of manufacturing punched cards that is simple, efficient, extremely accurate, foolproof, consistent and capable of utilizing existing production equipment except for the special cutting dies involved.

Other objects will be in part apparent and in part pointed out specifically hereinafter in connection with the description of the drawings that follow, 4and in which:

FlGURlE l is a plan view showing the ini-tial cut made in the sheet of card stock which forms the first of the two cards;

FlGURE 2 is a plan view similar to FIGURE l showing the sheet of stock following the second cut that forms the other of the two cards in end-.to-end face up relation to the first but joined thereto along a portion of their common edge to form a connecting tab;

FIGURE 3 `is la plan view of the cutting die used to produce the cards; and,

lFlGUlE 4 is a plan View similar to both FIGURES l and 2 showing one of the finished `cards after the excess stock has been removed from its margins, it has been printed and subjected to the third and linal cut which separates same from its companion card.

Referring now to the drawings for ya detailed description of the present invention and, in particular, to FIG- URE 3 for this purpose, the cutting diel which has been indicated in a general way by reference numeral l@ will be seen to comprise `a base-plate l2 to the top surface of which is attached an upstanding edge-forming knife 14 land ya plurality of removable hole-punching cutters lr6 arranged to produce four separate and distinct codes, one in each of the four quadrants. llhe arrangement of the four codes and their printed deciphers (not shown) follows the conventional practice that has already been described in considerable detail and which has been identitied in FIGURES l, 2 and 4 as Codes l, 2, 3 and 4. These hole-cutters or punches lo are screwed or otherwise removably attached to the base-plate because they provide the means by which vthe codes are changed. For example, in the the drawings, reference numeral lll-l identiiies the punchamounting holes in the baseplate and, where no punch is shown, a blank will appear on the card.

ln the particular form illustrated herein, the areas of the die containing the hole-'cutters and edge-forming knife are bordered by wooden blocks 2li topped with sponge rubber that .projects above the cutting edges in position to engage the card yand hold saine in accurate position while it `is being cut. The rubber, of course, compresses to the extent required to permit the knife and cutters to contact the card and perform their respective functions. The particular shape .and arrangement of these compressible holding elements Ztl is a matter of choice and may be varied considerably to suit individual needs.

The edge-forming knife ld is the most critical part of the die as it enables the method to be employed by which a pair of `cards can be blanked from the same sheet of stock in face up end-.to-end relation with all four edges precisely located relative to `the code-forming indicia. At this point, it should be mentioned that while FlG- URES l and 2 show the card lying on its side and FIG- URE 3 reveals the die in the same position, it being the one .actually used during the cutting operation, for purposes of clarity it is desirable 4to describe both the card and die in relation to one of the four positions the card occupies .in the data-processing machine, i.e., that shown in FIGURE 4. Thus, portion 22 of Athe edge-forming knife ld located to the .right in FIGURE 3 will be referred to as the top of the knife because it forms the top edge of the card when in position as shown in FIG- URE 4. Similarly, the upper and lower horizointal portions of the knife that have been designated by reference numerals 2li and 26, respectively, form the left and right iside margins of the card; whereas, the leftJhand portion 2S forms the bottom edge.

The side-edge forming portions Z4 and 26 of the knife are located in spaced parallel relation to one another and are primarily joined to both the top and bottom-edgefo-rfming portions 22 and 28 'by rounded corners Sil that prevent the corners of the card produced thereby from becoming dog-eared through continued use and handling. The ltop-edge forming portion 22 is continuous and substantially parallel to the interrupted bottom-edgeforming portion 23. As has already been mentioned, all four of the edges of the die, including the interrupted edge 2S, must produce edges on the card bearing a very precise relationship to at least one of the codes produced thereby. Ord-inarily, stops engaging two `adjoining edges of the card are required as a minimum, preferably the bottom and one side edge. If, on `the other hand, the card enters the machine through a slot in the side thereof, stops may be provided yto engage both the top and bottom edges as well as one side edge. Similarly, as is the case with the coded card illustrated in the accompanying drawings which is the type to be inserted through a `top-opening slot, guide-stops are provided along both side edges, and on the bottom as shown in FIGURE 4 which will be discussed in detail presently. In any event, the spacing between all four edges and the four sets of code-forming holes becomes critical.

Now, if these cards are cut one-at-a-time and cornpletely separated from the stock, these dimensional relationships present no particular problem to maintain within the allowable `tolerances and they become merely a function of the accuracy of the die. Even when fabricated two-at-.a-time in face-up end-to-end relation, the problems associated with locating the punch holes accurately with respect to the side and top edges are no greater than those encountered when making the cards singly for obvious reasons, however, the common bottom edge does cause real diiiiculties and it is to this phase of the manufacturing process that the invention is primarily directed.

. hand corner.

Before describing in detail the interrupted bottom edge ZS of the die knife, it will be well to explain briefly the structure of the stop on the machine that is engaged thereby which makes the two-at-a-time face-up method workable. With reference to FIGURE 4 of the drawings, it will be seen that the stop-forming guides 32 and 34 of the machine that engage the side margins 36 and 38 of the card are continuous; whereas, stop 4t) that supports and engages the bottom edge 42 is of the interrupted type having at least two spaced points or areas of contact. ln the particular form shown, stop 40 consists of a pair of pins located on opposite sides of the vertical centerline adjacent the lower corners. Therefore, as long as those sections of the bottom edge 42 that actually engage stop dit are accurately located with respect to the side edges, top edge and punched holes, it makes no difference whatsoever how inaccurately the remaining tab-forming section 44 is cut, because it performs no function as far as positioning the card is concerned. ln the particular form shown a single so-called tab section 44 separates the spaced stop-engaging sections 4Z of the bottom edge and it is this tab section that provides the common connecting web for the two cards. It is quite obvious that more than one tab section could be provided separating several accurately cut'stop-engaging sections if the requirements of the machine were such that more than two spaced supporting stops 4t) were used. Also, it is possible that a machine could employ an interrupted stop on an edge other than the bottom edge which would be continuous and, if this is the case, the cards should be joined together along the edge that is to engage the interrupted stop rather than the one shown.

Thus, referring once again to FGURE 3, it will be seen that the bottom or interrupted edge-forming portion 28 of knife i4 comprises a pair of relatively short sections 46 joined to the bottom ends of side-edge-forming portions 24 and 26 by curved corners 3i) and extending inwardly therefrom in aligned but spaced relation terminating in free ends 4S that curve away from the top knife edge 22. Knife 14, therefore, makes a continuous cut along the top and both side margins of the card but leaves a tab 44 uncut along the bottom edge thereof between sections 46 of the blade. These sections 46 are parallel to the top knife edge 22 and essentially perpendicular to the side edges thereof.

From an examination of FIGURE 3, it will be noted that a knife blade 50 also depends from the baseplate extending between the curved end portions 43 of bottomedge-forming sections 46 of the main blade. Blade Si), however, has its cutting edge recessed slightly beneath the edge of the main blade and, therefore, it does not cut through the card stock but merely embosses a line n the connecting tab 44 indicating the location of the final cut which will separate the two cards one from the other once the printing operation has been completed. Actually, this auxiliary blade can be eliminated altogether. When used, however, it should emboss the cut-oli line on the tab outside the interrupted edge deiined by sections do of the main blade if the severing out is to be made in this line; otherwise, the accurate bottom edge 42 of the card will be removed and the close tolerances to which the card is cut will be destroyed.

The die blanks out only one card per impression and, therefore, covers only one-half of the baseplate. lThe actual manufacturing operation is perferably carried out on a platen-type printing press which automatically feeds the stock onto the platen, aligns it, makes the cut, and restacks the once-cut cards. Thereafter the cards are turned over end-for-end and fed once again through the press to blank the second card. Each cut, however, produces all four codes. Code l is on the face of the card in the upper left-hand corner. Code 2 is upside down on the Same face of the card as Code 1 but in the lower right- Code 3 is impressed on the same face of the card as Codes l and 2 in the upper right-hand corner and right-side-up; however, the holes that form same are arranged to be read by the machine when the card is iiipped over face down, or more properly, to the rear as indicated by the dotted lines. Similarly, Code 4 is punched from the front face of the card in the lower left-hand corner. lt is both upside down and reversed so as to be read in the upper left-hand corner by thc machine when the card is flipped over placing the front face to the rear and also the top and bottom edges reversed as indicated by the upside down dotted line lettering Code 3.!)

The sequence of operation will now be set forth in detail in connection with FiGURES l, 2 and 4. The baseplate is mounted in the press with a die on either side although for purposes of the present description it will be assumed that the die is on the right as shown in FIG- URE 3. A stack of blank cards cut to provide a small border of between approximately 1/s and 1A inch is placed in the pick-up portion of a platen press. As the press is set into operation the cards are picked up one-at-a-time by the over-hanging iingers provided on such machine and placed down on the bed of the press when one side edge and the bottom edge are engaged by aligning stops provided for the purpose and which have been indicated more or less schematically in FlGURES l and 2 by reference numerals 52 and 54. These stops locate the blank card in correct relation to the die and form no part of the present invention as they are standard equipment on a platen press. As the press closes, the die engages the card and blanks out the first card 56 as shown in FIG- URE l; whereupon, it is removed and stored in a second ack of once-cut cards.

Next, with the die still in the same position, the stack of once-cut cards is turned over end-for-end to place the rst card Se on the left side face down in the hopper of the press preparatory to blanking out the second card. The operation is then repeated to blank out the second card 53 in end-to-end adjoining relation to the first card 5o as shown in FIGURE 2. Tab 44 remains uncut and connects the bottom edges of both cards together.

At this point it should be mentioned that insofar as making a card to the exact size required is concerned, it makes no difference where it is located relative to the edges of the blank card so long as it does not fall outside the border of the card or move over onto the other half and interfere with the second card, In other words, assume that the blank is not fully seated against either of the stops 52 and S4 when the first card 56 is blanked out. The precise relationship between the stop-engaging edges thereof and the punched holes is unaffected and, when the second card is blanked out, all that changes is the width and perhaps the shape of tab 44 which has no eiect on the proper registry of the card in the machine. From another standpoint, namely, subsequent forming operations, it is preferable to have both cards located rather accurately with respect to the borders of the blank card as this simplifies the trimming operations, removal of the disks from the die-cut holes and separating the cards along the connecting tab d4.

Before separating the cards, the borders du are trimmed therefrom and discarded. While these borders have been cut all the way through the card, they generally remain in place until pulled away by hand. This can be done a stack-at-a-time and need not be done to single cards.

Next, the cards are placed by the stack in a suitable jig (not shown) provided for this purpose which holds the stack square, aligns the die-cut holes vertically and provides holes underneath each of the possible hole locations to receive the disks removed therefrom. A simple pin-type punch is then gently driven through each punched hole to remove the disks therefrom.

Following the trimming operation, the cards are printed two-at-a-time resulting in substantial savings in both time and labor. llt is most important that the cards be printed before they are separated one from the other as it is this operation in which the major economies are realized. The cutting operation utilizing a single-cut die to blank out only one card at a time from a piece of stock capable of producing two cards offers little, if any, advantage over cutting out one card in its entirety if it were not tor the advantages realized in the printing step.

Finally, the entire stacl: of trimmed, stacked and printed cards is placed on a cutter which separates the lirst and second cards along tab 44. As aforementioned, it makes no difference at this point that the cutter leaves more of a tab on one card than another as the tab has no etiect on the ultimate registry of the cards in the dataprocessing machine. From a practical standpoint, two severing cuts are usually made, one along embossed line d2 at the base or bottom of cards 56 and a second along embossed line e4 (FlGURE 2) of second card 53 to remove the tab 44 left thereon. As long as these severing cuts are made outside interrupted edge 42, they cannot affect the dimensional accuracy of the card.

FlGURE 4, of course, shows the finished card as it is used in the data-processing machine where it is held in transverse alignment by stops 52 and 34 and supported in vertical alignment by interrupted stop Having thus described eatures of the coded programming cards and methods used in forming same, it will he seen that the many Worthwhile objectives for which they were developed have been achieved. Although but one specic embodiment of the card and method of fabricating same have been illustrated and described in connection with the accompanying drawings, we realize that other designs and methods may well occur to those skilled in the art within the broad teaching hereof; hence, it is our intention that the present invention be limited only to the extent such limitations are set forth expressly in the appended claims.

What is claimed is:

1. The method of forming a duplicate pair of substantially rectangular cards from a single generally rectangular sheet of card stock which comprises the steps in sequence of, rst die-cutting not more than one-half of the sheet to sever three of the four edges of a single card therefrom while leaving said card connected to said sheet along an intermedia e portion of the fourth edge located adjacent the transverse centerline of the sheet, said connecting portion forming a tab interrupting the fourth edge between its ends and extending along said transverse centerline of the sheet, second die-cutting the other halt` ot the sheet to sever three of the four edges of a second the several useful and novel card therefrom while leaving said second card connected to the first by means of said common tab-forming portion, and, third, separating the two cards by cutting along the interconnecting tab so as to leave the partially-termed fourth edges of both cards intact.

2. The method as set forth in claim 1 including the operations of die-cutting a plurality of code-forming apertures in one face of each card simultaneously with the formation of the edges thereof and thereafter apply* ing a printed decipher of the code simultaneously to the face of both cards prior to separating one from the other.

3. The method as set forth in claim 1 including the step of turning the sheet or" card stock upside down and reversing same end for end between the steps of forming the edges of the first and second cards.

4. The method as set forth in claim l including the steps of removing the severed borders and any card stock material remaining within the die-cut apertures following formation of both cards but before they are separated one from the other.

5. rhe method as set forth in claim 2 including the step of turning the sheet of card stock upside down and reversing same end for end subsequent to formation of the I'irst card and the apertures therein but before the second card is formed.

References Cited by the Examiner UNlTED STATES PATENTS 354,170 12/86 Myers 83-36 X 609,007 8/98 Butler lOl-227 1,105,995 8/14 Nichols 234-21 1,942,145 1/34 Knight 83-682 2,141,121 12/38 Attwood 83-917 X 2,180,331 11/39 Hughes 83-36 2,200,886 5/40 Kuhn S33-903 X 2,207,650 7/40 Winkle 83-903 X 2,596,911 5/52 Nelson 83--620 X 2,625,223 1/53 Lund 83-903 X 2,648,381 8/53 Engel 83-36 2,655,212 10/53 Stewart 83-917 X 3,026,029 3/62 Daniels 235--51.l2 3,034,712 5/62 Mead 23S-61.12

ANDREW R. JUHASZ, Primary Examiner.

WlLLlAM W. DYER, in., MALCOLM A. MORRlSON,

Examiners. 

1. THE METHOD OF FORMING A DUPLICATE PAIR OF SUB STANTIALLY RECTANGULAR CARDS FROM A SINGLE GENERALLY RECTANGULAR SHEET OF CARD STOCK WHICH COMPRISES THE STEPS IN SEQUENCE OF, FIRST DIE-CUTTING NOT MORE THAN ONE-HALF OF THE SHEET TO SEVER THREE OF THE FOUR EDGES OF AS SINGLE CARD THEREFROM WHILE LEAVING SAID CARD CONNECTED TO SAID SHEET ALONG AN INTERMEDIATE PORTION OF THE FOURTH EDGE LOCATED ADJACENT THE TRANSVERSE CENTERLINE OF THE SHEET, SAID CONNECTING PORTION FORMING A TAB INTERRUPTING THE FOURTH EDGE BETWEEN ITS ENDS AND EXTENDING ALONG SAID TRANSVERSE CENTERLINE OF THE SHEET, SECOND DIE-CUTTING THE OTHER HALF 